Stand-up flexible pouch and method of forming

ABSTRACT

A stand-up flexible pouch for packaging a product and a method of forming and filling the pouch is provided. The pouch includes a panel forming a body of the pouch using a flexible material having an inner surface and an outer surface. A rib is integrally formed in the pouch body, and the rib is spaced a predetermined distance from an edge of the pouch body. The pouch also includes opening means integral with the panel for accessing a product contained within the pouch. The method of forming the pouch thermoforms a rib in each panel of material across multiple lanes of a high speed machine.

CROSS-REFERENCE TO RELATED APPLICATIONS

This application claims priority of U.S. Provisional Patent ApplicationSer. No. 60/909,797 filed on Apr. 3, 2007, which is incorporated hereinby reference.

FIELD OF THE INVENTION

The present invention relates generally to a flexible pouch forpackaging a product and, more specifically, to a stand-up flexible pouchfor packaging a product and a method of manufacturing the same.

DESCRIPTION OF THE RELATED ART

Various factors influence the type of disposable, portable containerused to store a product, including volume of the product. Examples ofcontainers include a box, a can, a bottle, or a flexible pouch. A largervolume of the product may be stored in a barrel or keg or the like.While barrels and kegs work well for larger quantities, they areexpensive, and may be subject to abuse by consumers, which impedesreusability. Flexible pouches are available for storing limitedquantities of a product, such as fruit juice and the like. Flexiblepouches are convenient to both the consumer and manufacturer. However,their use in storing larger quantities of a product is limited, sincethe flexible pouch tends to collapse as the product is removed. Thus,there is a need in the art for a flexible pouch capable of retaining itsshape even as the product is removed, and an improved method of makingsuch a flexible pouch.

SUMMARY OF THE INVENTION

Accordingly, the present invention is a stand-up flexible pouch for aproduct, and a method for manufacturing the pouch. A stand-up flexiblepouch for packaging a product and a method of forming and filling thepouch is provided. The pouch includes a panel forming a body of thepouch using a flexible material having an inner surface and an outersurface. A rib is integrally formed in the pouch body, and the rib isspaced a predetermined distance from an edge of the pouch body. Thepouch also includes opening means integral with the panel for accessinga product contained within the pouch.

One advantage of the present invention is that a stand-up flexible pouchfor a product and an improved method of making the flexible pouch isprovided. Another advantage of the present invention is that a stand-upflexible pouch and method of making the flexible pouch is provided thatutilizes a laminate material that includes a laminate structure of PET,foil, nylon, LLDPE and cast polypropylene layers. Still anotheradvantage of the present invention is that a stand-up flexible pouch andthe method of making the flexible pouch is provided that has a barrelshape. Yet a further advantage of the present invention is that astand-up flexible pouch and method of making the flexible pouch isprovided that includes an integrally formed rib to add rigidity to thepouch and assist the pouch in retaining its shape as the product isremoved. A further advantage of the present invention is that a stand-upflexible pouch and method of making the flexible pouch is provided thatis cost effective to manufacture. Still a further advantage of thepresent invention is that the flexible pouch can stand uprightunsupported. Yet still a further advantage of the present invention isthat a stand-up flexible pouch and method of making the flexible pouchis provided that can store a liquid product, including a carbonatedproduct or a product having an alcohol content.

Other features and advantages of the present invention will be readilyappreciated, as the same becomes better understood after reading thesubsequent description taken in conjunction with the accompanyingdrawings.

BRIEF DESCRIPTION OF THE DRAWINGS

FIG. 1 is an elevational view of stand-up flexible pouch for a product,according to the present invention.

FIG. 2 is a perspective view of a stand-up pouch for a product,according to the present invention.

FIG. 3 is an elevational view of another shaped stand-up flexible pouch,according to the present invention.

FIG. 4 is a sectional view taken along line 4-4 of a rib formed in thepanel of the pouch, according to the present invention.

FIG. 5 is an elevational view of another stand-up flexible pouch,according to the present invention.

FIG. 6 is a perspective view of still another example of a stand-upflexible pouch, according to the present invention.

FIG. 7 is a perspective view of a further example of a stand-up flexiblepouch, according to the present invention.

FIG. 8 is a flowchart of a method of forming the stand-up flexible pouchof FIGS. 1-7, according to the present invention.

FIG. 9 is a diagrammatic view of a form-fill-seal machine for use withthe present invention.

DETAILED DESCRIPTION OF THE PREFERRED EMBODIMENTS

Referring to FIGS. 1-7 a stand-up flexible pouch 10 is illustrated. Thepouch 10 may be filled with a product (not shown) and sealed. It iscontemplated that the pouch may contain a single portion or multipleportions of the product. For example, the pouch may contain twentyliters of the product. Various shapes are contemplated for the pouch.The pouch 10 may have a generally cylindrical shape, a box-like shape,an hourglass shape, a barrel shape or another shape. In this example,the product is a liquid. The liquid may be a consumable product havingan alcohol content, such as wine, beer or liquor, or the like. Theproduct may be a carbonated product, such as a sparkling wine or juiceor the like. The liquid may be any other type of product, such asshampoo or liquid soap or the like. An example of a pouch for acarbonated liquid is disclosed in commonly assigned PCT PatentApplication No. PCT/US03/034396, which is incorporated herein byreference.

The stand-up flexible pouch 10 is preferably formed from a roll ofpreprinted material of extruded or laminate layers. The material istypically a three, or four, or five or more gauge material or multiplelaminations of material or the like. The outer layer is usuallypreprinted. Alternatively, at least a portion of the material may be notprinted, i.e. translucent, in order to view the contents containedtherein, as shown in FIG. 7 at 48 as a window. The clear portion couldalso be in a gusset or insert. The outer layer may include preprintedinformation, as with a label or shrink sleeve. The pouch may includemore than one type of material.

The choice of sheet layer material is non-limiting, and is influenced byfactors such as the product contained in the pouch, the shape of thepouch, or the anticipated use of the pouch. One example of a laminatematerial structure includes at least one layer of virgin polyethyleneterephthalate (PET), at least one layer of aluminum foil and anotherlayer such as EVOH, PET, polyethylene or nylon or the like. Another typeof laminate material structure may also include a metalized foil paperlayer laminated to a cast polypropylene layer and another layer of PET,polyethylene or EVOH. There may be a fourth layer of nylon. Similarly,the laminate structure may include a cast polypropylene (CPP) layer, apolyethylene (PET) layer, a foil (AL) layer, a nylon (ONO) layer andanother CPP layer. Another structure is the use of nylon, foil, nylonand cast polypropylene (ONO/AL/ONO/CPP) or CPP/NY/AL/CPP, orPET/AL/NYLON/CPP, or ONO/AL/COEX-ONO-LDPE.

For certain products, such as a carbonated liquid or beverage, certainmaterials are somewhat permeable, thereby allowing loss of the internalcarbon dioxide gas from the pouch and its replacement with oxygen. Thepresence of oxygen in the filled pouch increases the chance of bacteriaforming, or may affect the taste. Therefore, material structures thatinclude CPP are well suited for packaging a beverage, such as wine orbeer or other carbonated fluids, to add strength to the walls of thepouch, preserve the carbonation, and protect with the nylon the AL layerfrom cracking. Carbonation is beneficial since it acts as a microbiocideand preserves the flavor and aroma of the products. The use of castpolypropylene laminate material also assists in retaining the filledshape of the container, even as the product is removed from the pouch10. A further example of a laminate material structure is CPP/AL/ONO/PE.This structure works well when the product has a short shelf life, andthe nylon eliminates stretching or cracking of the AL layer. Still afurther example of a material structure is a co-extruded laminate suchas PET/CO-PP/AL/NY/LLDPE. It should be appreciated that the CO-PP layercan include multiple layers, such as three in this example. An exampleof a material structure for a white wine product is PET/EVOH/PE orAL/PET/NY/PE. Similarly, a material structure for a red wine productincludes PET/EVOH/PE or AL/NY/PET/PE.

Other film structures may also be utilized that offer protection fromsunlight, as well as organoleptic protection from the development ofundesirable flavors. In addition, the selected material may beorganoleptic compliant in order to avoid the transfer of odorcontaminates to the product, or product contamination during the shelflife period of the product.

It should be appreciated that for certain types of filled pouches storedat ambient temperature, the laminate material may start to creep after aperiod of time, such as within ten days. For a carbonated product, thecreepage results from carbonation expansion. The use of a laminatematerial with an extrusion layer contains “creepage” or “stretch” of thefilm.

The pouch 10 is formed from at least one panel of material. The panelhas an inner surface 11 a that is adjacent the product, and an outersurface 11 b. The pouch formed out of the panel has a front wall 12 anda back wall 14. Each wall 12, 14 is further defined by an upper edge 16,an opposed lower edge 18, and side edges 20 extending therebetween theupper and lower edges 16, 18. The edges of the panel are joined to forma sealed seam 22. In an example of a pouch formed using a single panelof material, the panel edges may be joined along a center seam. The seammay be a flat seam or a fin style seam or the like. In an example of apouch 10 formed using two sheets of material, the panel edges may bejoined along two side seams 22. Again, the side seam may be a flat seam,a fin style seam or the like.

The wall of the pouch includes an integral rib 50 formed in the panel ofmaterial, and a wall may include a plurality of ribs. The rib 50 isselectively shaped to form a shaped edge of the pouch as shown at 26 andoriented to provide structural rigidity to the pouch 10. The arrangementand shape of the rib adds structural strength to the pouch wall, so thatthe pouch can stand upright unassisted, regardless of the pouch volume.Further, the rib 50 may have a shape and arrangement that generallydefines an overall shape of the pouch 10. The pouch 10 may include aplurality of ribs in order to define the shape and structure of thepouch. The rib 50 is positioned a predetermined distance from the edge,such as 1″. In an example, the rib 50 has a generally verticalorientation, and is positioned adjacent a side edge 20 of the pouch. Inanother example, one or more ribs 50 are positioned adjacent each sideedge 20 of the pouch. In still another example, the ribs 50 arepositioned a varying distance apart. In yet another example, the ribs 50are spaced an equidistance apart. Each rib 50 has a predetermined lengthand cross-sectional shape. The rib length may be selectively determined,depending on factors such as the size of the pouch 10, or desiredstructural rigidity for the pouch 10, or the like. For example, the rib50 may extend along about 80% of a length of the finished pouch 10.Referring to FIG. 4, the rib 50 may have a uniform cross-sectional shapeextending the length of the rib. Similarly, the rib 50 may have across-sectional shape that varies along the length of the rib 50. Anoverall height H of the rib 50 may be less than a thickness T of thepanel material. The rib 50 is formed in the inner surface of the panelof material, so that the outer surface of material is concave. The rib50 is formed by the application of heat to the panel of material. Forexample, a heat seal bar may be utilized to form the rib 50 in the panelof material.

The pouch 10 retains its predetermined shape even as product is removedfrom the pouch, due to the structural rigidity provided by the ribs. Forexample, the predetermined shape may be generally cylindrical, similarto a traditional metal barrel, or a cubical shape, similar to a carton,or the like. Other shapes are contemplated, depending on factors such asthe product contained therein, volume and use of the pouch.

The pouch 10 may also include an insert, sidewall or gusset 24. Thegusset 24 may be integrally formed in the panel, or a separate piece ofmaterial. The insert, sidewall or gusset material may be a differentstructure than that of the pouch body. The gusset 24 may be disposedbetween the front and back walls 12, 14, and positioned between the sideedges of the walls, the lower edges, the upper edges, or any desiredcombination. It should be appreciated that the shape of the gusset 24 isnon-limiting. For example, the gusset 24 may be generally wider at oneend and taper upwardly towards the opposite end. The gusset 24 may alsobe of a uniform width. The use of the gusset may be functional, i.e. itmay allow the pouch 10 to acquire another shape, such as cylindrical, orto stand upright. The gusset also enhances the strength and rigidity ofthe pouch 10 during filling and processing. A side gusset isadvantageous since it allows the walls of the pouch to expand as theinternal pressure within the pouch increases. A gusset positionedbetween the lower edges 18 of the pouch 10 may form a base, enabling thepouch 10 to stand upright unsupported. The edges of the gusset may besealed against the wall of the pouch, as shown in FIG. 6 at 25.

Similarly, the pouch may include an insert. The insert is a generallyplanar member that is inserted between the walls 12, 14 of the pouch 10.The shape of the insert is non-limiting, i.e. square, round or oval orrectangular, and generally influences the shape of the flexible pouch.The insert may be positioned internally within the pouch or externally.Various materials may be utilized for the insert, such as foil,cardboard, plastic, nylon, laminate or the like. Further, the insert maybe formed from a printed material, or it may be clear. In one example,the insert is inserted between the lower edges of the panel and sealedto the walls of the panel. The seal may be an ultrasonic seal or a heatweld or a combination of both or the like. The insert may include anintegral opening means, such as a fitment. Similarly a first insert maybe positioned between the lower edges of the panel, and a second insertpositioned between the upper edges of the panel. The first insert mayinclude an integral opening means, such as a fitment.

The pouch 10 also incorporates an opening means 28 for accessing thecontents of the pouch. Various types of opening means 28 are known inthe art for this purpose, and are non-limiting. The position of theopening means 28 is determinable by many factors, such as the type ofproduct contained or type of opening means or use of the pouch or thelike. For example, the opening means 28 may be positioned in an upperedge, a lower edge or side edge, or front wall or back wall, or on aninsert or gusset. It should be appreciated that the opening means 28 maybe incorporated into the pouch 10 prior to filling the pouch 10, orafter filling.

An example of an opening means is a tear-off portion 30. The tear-offportion 30 usually has an integral tear notch 32 and tear line, forremoving a designated portion of the pouch to access the productcontained therein. The tear-off portion 30 could be utilized inconjunction with another opening means, such as a zipper. The zipperopening means is a resealable zipper that provides a hermetic sealthrough interlocking teeth, such as a zipper that is sold under the nameTopTite™. The zipper may be used with another opening means. Anotherexample of an opening means 28 is a weakened, straw-pierceable portionin the pouch for receiving a straw within at least one of thecompartments. A further example of an opening means 28 is a pull tabcovering an opening in the pouch.

Still another example of an opening means is a spout fitment 34 thatincludes a cap 36 for containing the product within the pouch. Thefitment 34 includes a base 38, and a spout 40 projecting upwardly fromthe base 38. The base portion includes a centrally located passagewayextending through the center of the fitment, to provide access to thecontents of the pouch. An outer surface of the base portion forms aseal-engaging surface that is sealed to the panel in a manner to bedescribed. The spout 40 is generally cylindrical in shape, and includesa centrally located passageway that is continuous with the centralpassageway of the base portion 38. The spout 40 may be sealed, such asby a sleeve or a cap. Various styles of caps 36 may be utilized inconjunction with the spout, such as a removable cap, or a slideable capor the like. The removable cap can be the traditional round shape.Alternatively, the cap 36 can have another shape, such as oval. The cap36 may include a tamper-evident feature. In addition, the cap 36 may bepermanently retained on the spout to be environmentally friendly. Thecap 36 and fitment 34 can be made from a variety of materials. Forexample, the cap 36 may be made from plastic, such as reground resins.The fitment 34 may be made of polypropylene (PP), depending on theproduct. The fitment base 38 is sealed into the upper edges of the panelusing a sealing means, such as an ultrasonic seal or a heat weld, or thelike. The spout 40 may include a removable seal to prevent leakage ofthe product or evidence of tampering. The cap 36 may include an insertof an oxygen absorbent material.

The pouch 10 may include an angled top seal 42 as described in commonlyassigned U.S. Patent Application Ser. No. 60/779,796, which isincorporated herein by reference. The position of the angled top seal 42is dependent on the location of the opening means 28. In one example,the angled top seal 42 extends between one side edge and the upper edge,and the opening means 28 is located between the other side edge 20 andthe upper edge 16. The shape and position of the angled top seal 42facilitates the removal of product from the pouch 10 by directing theflow of the product towards the opening means 28. The angle top seal mayhave a radius to keep the interior of the pouch rounded. The angle topseal preferably reduces the right angle corner headspace. This isadvantageous because it assists in pouring the product, reducesheadspace (and oxygen), and influences the shape of the pouch.

It should be appreciated that the barrel-shaped flexible pouch 10 mayadvantageously include other features that are known in the art. Forexample, the pouch 10 may include a guide pocket formed in a wall 12, 14of the pouch 10 prior to filling and sealing, to facilitate theseparation of the front and back walls 12, 14 prior to the filling ofthe pouch 10. An example of such a pouch is disclosed in commonlyassigned U.S. patent application Ser. No. 10/310,221.

The pouch 10 may include other features, such as an ergonomic shape. Anexample of an ergonomically shaped pouch for a carbonated beverage isdisclosed in commonly assigned U.S. patent application Ser. No.11/454,241 which is incorporated by reference. The flexible pouch 10 mayinclude a feature such as an outer layer or sleeve covering the outersurface of the pouch. The sleeve may be a label containing informationabout the product, such as a barcode or the like. The sleeve may coveronly a portion of the pouch outer surface. Preferably, the sleeve isshrunk over the outer surface of the pouch 10 after the pouch 10 isformed and filled with the product. The sleeve is advantageous becauseit covers the side seam. It also adds one or more layers of material tostrengthen the pouch and improve its durability. Various types ofmaterial may be utilized for the sleeve, such as paper or plasticincluding PET or PVC and the choice is non-limiting.

Another example of a feature is a hanging aperture 44 formed in a seamfor supporting the pouch by a support means. One or more hangingapertures may be formed along an edge of the pouch 10 for receiving afastener, such as a clip or the like. The aperture may be used totransport or display the pouch. The aperture 44 may have various shapes,such as round or curved. Advantageously attaching the pouch anotherobject via the hanging aperture enhances the convenience of the flexiblepouch.

A further example of a feature is a tracking device 46 integrallylocated within the pouch 10 that includes electronic trackinginformation relevant to the pouch 10, as described in commonly assignedU.S. patent application Ser. No. 11/686,666, which is incorporated byreference. The tracking device 46 may be an electronic tag, such as aRadio Frequency Identification (RFID) transmitter. The tracking device46 can store a predetermined amount of electronic information. Anexample of the information is unique tracking information for aparticular package 10. For example, the tracking device 46 can provideinformation about the status of the pouch 10, such as physical locationof the pouch 10, or age of the pouch 10 or the like. In addition, thetracking device 46 can be utilized for inventory control, delivery,purchase behavior, returns, pricing, and other tracking purposes. Thetracking device 46 is in communication with a receiver (not shown) forreading the information. The receiver may be a computer system having amemory and a processor, a handheld device for receiving an RFID signal,or any other type of device capable of electronic communication with thetracking device 46. The receiver may be a transceiver capable ofemitting a radio signal that initiates transmission of information fromthe tracking device 38. Although the packages are individually read, theRFID tag may be advantageously read at a faster rate than using abarcode in conjunction with a barcode scanner, since the packages arenot physically scanned on an individual basis. In addition, the signalfrom the RFID tag may be advantageously read through an outer layer ofmaterial, such as a packaging material, or under various environmentalconditions. Another advantage is that the tracking of the physicallocation of the package may be electronically monitored within apredetermined geographical range. The tracking device 46 may beintegrally embedded in the pouch 10. The tracking device 46 may beinserted in an air pocket formed within one of the gusset apertures.Alternatively, the tracking device 46 may be inserted in a sealedportion of the pouch, and an air pocket is formed around the trackingdevice 46 during application of the seal. The tracking device may beintegrally formed in the opening means.

The pouch 10 may include other features as a result of a secondaryprocess after it is filled with the product. For example, the filledpouch 10 may be frozen. Alternatively, the filled pouch 10 may bepasteurized in order to have an extending shelf stable life underambient temperature.

It is contemplated that the flexible pouch 10 may incorporate any of theabove-described features in any combination. For example, the pouch 10may include an insert in the bottom portion of the pouch and a taperedtop portion, or an insert in the bottom portion of the pouch and a spoutand cap in the top portion of the pouch. In addition, the finished pouchmay assume various shapes, such as cylindrical, cubical, and conical,hourglass or barrel shaped or the like, as influenced by the type ofproduct and intended usage of the pouch. The pouch may assume atraditional shape for a product, such as a keg for beer.

In addition the barrel-shaped flexible pouch may include an outer frameto allow for stacking of the pouches. The frame can be of a suitablematerial, such as metal, plastic or corrugated paper or the like.

Referring to FIG. 8, a method for forming and filling the stand-upflexible pouch 10 using a high-speed machine is illustrated. The methodbegins in block 100 at a first station with the step of forming the bodyof the pouch. For example, a roll of laminate material, as previouslydescribed, is unrolled along a horizontally oriented plane. The initialwidth of the roll of material is determined by the desired finished sizeof the pouch 10 and the number of pouches to be obtained from the width.For example, three or four or six pouches, representing six to twelvepanels, can be obtained from a width of the roll of material on amultiple lane machine. Each panel has an inner surface and an outersurface. One layer of the material is preferably preprinted withinformation or locating indicia (not shown), such as a registrationmark. The registration marks are located on the material to denote anedge of a wall 12, 14. The registration marks are read by an opticalreading device (not shown), such as a scanner or registration eye, toindex the material in a predetermined position at the cutting station.The preprinted information may include labeling information thatdescribes the product contained within the pouch. In this example, thelayer of preprinted information is located on an outer layer of thematerial.

The methodology advances to block 105 and a rib 50 is formed in thepanel of material corresponding to each pouch formed from the panel ofmaterial. In this example, the rib 50 is formed using a thermoformtechnique, such as a heat bar. As previously described, features of therib 50, such as orientation, shape, number, size, height, curvature,etc., are dependent on various factors, such as the size of the pouch,the product contained in the pouch or the shape of the pouch 10.Additional ribs 50 may be spaced a predetermined distance apart from afirst rib, or otherwise positioned where necessary to provide strengthor shape to the pouch. It should be appreciated that for multiple panelsand lanes, the rib is simultaneously formed in each panel across eachlane.

The methodology advances to block 110 and a feature, such as a gusset 24or insert, is optionally positioned between the aligned first and secondunrolling sections of material. In addition, an opening means 28 may beapplied at this time. For example, an opening means, such as a spoutfitment 34 may be applied.

The methodology advances to block 115 and the edges of the panel aresealed together to form the body of the pouch, such as the side edges,or the upper edge or the lower edge. An edge, such as the upper edge,may be left open for filling, or all of the edges may be sealed. In thisexample, the open edge is designated the upper edge, as a reference. Forexample, fitment 34 may be sealed between an edge, if the pouch 10 isfilled through the fitment 34. The edges to be sealed generally dependson the type of fitment, product or filling technique.

The seal used to form the seam 22 can be a permanent seal, a temporaryseal, or a frangible seal. Various types of seals are available, such asa single seal, a double seal, or an insulating seal, or the like.Various sealing techniques are known in the art to form each seal, and acombination of sealing techniques may be utilized. The seals may be aheat weld formed by applying heat and compression, or an ultrasonic sealformed using vibrational energy, or a combination of heat and ultrasonicseals. It should be appreciated that a previous seal may be absorbedduring the sealing process.

The side seal may be an overlap seal, whereby the side seal extendsalong the side edge of the panel and a predetermined distance along theupper edge, and a closing seal for the upper edge overlaps the sideseal. An angled top seal 42 may also be applied at this time.Advantageously, the seals may be shaped. The seal may have a curvilinearshape so as to avoid sharp radiuses at the interior corners of thepouch. A seal having an interior edge that is rounded facilitatesremoval of the product.

Various sealing techniques are contemplated. For example, an ultrasonicsealing process may be used. In another example, a heat weld thatincludes the application of heat and compression is applied. In stillanother example, the edges are sealed using a seal bar or forming platehaving a plasma coating. One advantage of the plasma coating is that theline speed may increase. Another advantage is that the coating makes thesurface of the seal bar or forming plate more resilient. When the sealbar is heated, the coating expands due to this resiliency. The shearstress on the inner edge of the seal is reduced; resulting in reducedcreepage of the material and greater durability of the seal. The plasmacoating reduces the opportunity for potential damage to the materialduring the sealing step. In this example, the plasma coating is asmooth, hard plastic that mimics glass. Since the outer layer ofmaterial is not weakened, there is no creepage of the outer layer.

A seal bar or forming plate may be used to apply any of the seals. Anexample of a seal bar is a generally rectangular member. The seal barmay include a cavity used to create an air pocket, or to conform to theshape of a member. The seal bar or forming plate may have a plasmacoating that makes the surface of the seal bar or forming plate moreresilient. When the seal bar is heated, the coating expands due to thisresiliency. The shear stress on the inner edge of the seal is reduced;resulting in reduced creepage of the material and greater durability ofthe seal. The plasma coating reduces the opportunity for potentialdamage to the material during the sealing step. In this example, theplasma coating is a smooth, hard plastic that mimics glass. Since theouter layer of material is not weakened, there is no creepage of theouter layer. An advantage of the plasma coating is that the line speedmay increase.

In still another example of a sealing technique, the side seal is atwo-step seal formed using more than one seal bar. One seal bar mayinclude the previously described seal bar cavity for forming an airpocket in the sealed portion. An example of a two-step seal is disclosedin commonly assigned U.S. patent application Ser. No. 11/551,071. Thetwo-step seal advantageously avoids the generation of ketones due toapplication of heat to the material. The first or inner seal is a lowtemperature seal. The second or outer seal is a high temperature seal.The second seal is spaced apart from the first seal by a predetermineddistance, to create an air gap. The first seal is a tack seal, such as 6mm wide, and is of a sufficient temperature so as to melt the layers ofmaterial and tack the edges together. The predetermined distance betweenthe first and second seal is ½-1 mm. The second seal is applied at ahigher temperature and pressure than the first seal. As a result, anygas, such as steam, ketones, aromatics or the like, is pushed in anoutwardly direction, out through the open edges of the panels, and notinto the pouch. Thus, the first seal prevents entry of contaminates intothe pouch to avoid organoleptic contamination. The heat weld may includea heat weld followed by a cold weld.

In an example, a feature, such as the fitment 34, as previouslydescribed, may be sealed within the walls of the pouch 10, such asbetween the upper edges 16. The fitment may be sealed using anultrasonic seal, or a heat weld, or by a combination of ultrasonic sealand heat weld, as previously described. An example of an ultrasonic sealfor a fitment is disclosed in commonly assigned U.S. patent applicationSer. No. 11/195,906, which is incorporated herein by reference.Accordingly, the base portion of the fitment is sealed between the wallsof the pouch using an ultrasonic seal, a heat seal, and then a coolseal. The heat seal melts a layer of the pouch material, and thematerial flows around the sealing ribs on the base portion, and fills inany void between the base portion and the wall of the pouch. The coolseal sets the seal and provides an attractive finish to the overallseal. Advantageously, fewer stations are required to seal the fitmentbetween the walls of the pouch, since a tack seal is eliminated.

The methodology advances to block 120, and each of the pouches formed inthe roll width of material are separated from each other in a cuttingoperation. For example, each section of material may be first separatedalong its width, or along the side edge of the panel. The section isthen separated into individual pouches. In this example, the width ofunrolling represents the side edges of the finished pouch. The materialis cut into a pouch 10 using a known cutting apparatus, such as a laseror punch or the like. The cutting apparatus forms a single cut in thematerial to separate the pouches. The length of the pouch 10 iscontrolled by the distance between the cuts.

Alternatively, consecutive pouches 10 are separated using a double cutprocess, whereby two cuts are made at the same time to separate theadjoining edges of the consecutive pouches at the same time.Advantageously, forming two pouches during the cutting operationeffectively doubles the assembly line speed.

The methodology advances to block 125 and the pouches 10 are finished.For example, an edge may be further trimmed to achieve a desired shape.In another example, the edge of the pouch may be trimmed to accommodatean opening means 28. It may be advantageous for the pouch corners tohave a radius, to eliminate right angles at the corners. In anotherexample, two legs are formed during the trimming operation, in order torecess the fitment. The hanging aperture 44 may be formed at this time.This operation may be performed using a cutter or a die cut or the like.

In another example of a finishing operation, a crease or guide pocketmay be formed in a top portion of each wall 12, 14 in a creasingoperation, in order to facilitate opening and filling of the pouch. Anexample of a method of forming a crease in a wall to facilitate openingthe pouch is disclosed in commonly assigned U.S. patent application Ser.No. 10/310,221, which is incorporated herein by reference. In stillanother example of a finishing operation, the sleeve is applied over theindividual pouch and shrunk to fit using an application of heat to thepouch.

The methodology advances to block 130 and the premade pouch 10 isdischarged from the form machine. The completed pouch may include anycombination of the above-described features. Further, the pouch may befilled through an open edge, i.e. upper or lower, or through thefitment.

The methodology advanced to block 25. The pouch is then transported tothe filling machine. The pouches may be loaded into a carrier andtransferred to a filling machine. It should be appreciated that thefilling machine may be integral with the pouch forming machine, or aseparate machine. This portability increases the flexibility of thepouch and may result in a manufacturing cost savings. The premade pouchmay be lifted from a box, magazine, vacuum belt and placed into thegrippers by a robot device, as shown in FIG. 9.

The pouch is unloaded from the carrier and placed in a holder for movingthe pouch between stations. An example of a holder is a cup or base orpuck having a shape corresponding to the shape of the pouch.Alternatively, the pouch 10 may be held using grippers (not shown) or arail as is known in the art. The methodology advances to block 140.

In block 140, the pouch 10 is opened in an opening operation. Varioustechniques are conventionally known in the art for opening the pouch 10.For example, the guide pocket formed by the crease in the front wall 12and back wall 14 facilitates opening of the pouch. A nozzle (not shown)may be mechanically lowered into the guide pocket to direct a stream ofcompressed gas into the guide pocket, to force the walls of the pouch 10away from each other. An example of a gas is carbon dioxide or nitrogenor the like. The blowing station may include a manifold, with a hoodextending over the top of the edges of the pouch as known in the art.The manifold has rows of apertures (not shown) formed above the upperedges 16 of the pouch 10. The hood is placed over the pouch 10 to assistin maintaining the air pressure in the pouch 10. The supply ofpressurized gas is directed through the aperture to form a plurality ofjets of pressurized gas or air. The jets are directed downwardly at thediamond-shaped openings formed at the upper edges 16 to assist inovercoming the surface tension of the pouch and assist in separation ofthe walls 12, 14. A diving rod (not shown) may then be used to make surethe pouch 10 is fully opened. If the pouch has a fitment, gas may beinjected through the spout fitment. After the pouch is opened, it may beinjected with super-saturated steam to eliminate any pathogens or thelike.

In block 145, the pouch 10 is filled with the product 58 in a fillingoperation. For example, a fill tube is lowered into the pouch apredetermined distance and the product 58 is dispensed into the openedpouch. The pouch 10 may be filled through an open edge, or through thespout 40 using the fill tube. If the pouch 10 is large, the pouch 10 maybe filled at more than one station. The product 58 is preferablydispensed at a predetermined temperature, depending on the type ofproduct. The fill tube may be raised out of the pouch at a predeterminedrate as the product is dispensed. For example, the fill tube may beremoved just ahead of the filling product 58.

If the product 58 is naturally carbonated, such as wine, beer or thelike, the pouch is preferably filled while immersed in a nitrogenatmosphere. If the product is not naturally carbonated and carbonationis desirable, it is immersed in a carbonator to introduce carbon dioxideinto the product. For example, carbon dioxide is introduced into coldwater or juice to provide a carbonated beverage. The product 58 maycontain a mixture of up to four volumes of carbon dioxide. It should beappreciated that the carbon dioxide masks any undesirable taste fromketones and other solvents released during the sealing process. Thecarbon dioxide also increases the pressure within the product so thatthe walls of the pouch are rigid after the top is sealed. The product 58is preferably filled at a temperature ranging from 29° F. to ambienttemperature. The filled pouch may have oxygen removed from the pouch.For example, the pouch may be flushed with carbon dioxide.

The pouches 10 may be moved to a station where any oxygen in the pouchresiding above the product is removed, if necessary. This can be done byproviding a hood or diving nozzle where oxygen is either evacuated orreplaced with carbon dioxide or nitrogen into the pouch to displace theoxygen. A diving nozzle may be used to inject the gas.

In block 150, the filled pouch 10 is closed. For example, if the pouchis filled through open edges, the open edge of the pouch is closed bysealing the edges together. The first or closing seal 52 may be anultrasonic seal, or an ultra pulse seal, or a heat weld or the like. Theclosing seal along an upper edge may overlap a side edge seal as shownat 54. If the pouch holds a carbonated beverage, the pouch may be sealedas described in commonly owned PCT Patent Application No.PCT/US03/034396, which is incorporated herein by reference. A secondcosmetic seal 56 may be applied above the first seal 52 for a carbonatedproduct. The second seal 56 may be a heat weld. For a carbonated seal,some of the product may be trapped between the first and second seals.This is advantageous since there is no gas in the head space, i.e. theregion between the product and the heat seal, and less pouch material isrequired. Another cosmetic seal may be applied across the first andsecond closing seals. If desired, an end of the seam may be tacked downin this operation as shown at 24.

Alternatively, the pouch 10 is filled through the spout fitment 34 andthe cap 36 is applied to close the pouch 10. The cap 36 may be atamper-evident cap for a carbonated product, containing an arrangementof thread and grooves as described in copending U.S. patent applicationSer. No. 11/551,071, as previously described. The cap 36 contains theproduct in the filled pouch 10, to prevent leakage of the product fromthe pouch 10. The complementary arrangement of threads and grooves inthe cap and spout provides for the controlled release of pressure fromthe pouch.

In an example of a push-pull cap, the plug is preassembled to thepush-pull cap and the plug and push-pull cap are pushed onto the spoutand retained by the spout. A tamper-evident outer cap may be disposedover the tube or slidable cap and fixedly retained by the tube spoutfitment as previously described. It should be appreciated that thetamper-evident outer cap may be pre-assembled to the slidable cap. Thisoperation is advantageous because it is fast, and cost efficient sinceit can be done at a high speed. In the example of an open-ended externaltube, the open end of the tube is sealed by applying a closing seal tothe upper edges of the cap. The closing seal may be an ultrasonic seal,or an ultra pulse seal, such as a heat weld or the like.

In an example of a zipper opening means, the open upper edge of thepouch is closed by engaging the zipper teeth. A closing seal may beapplied to the portion of the pouch outboard of the zipper, to furtherseal the upper edges 16 together using a closing sealing process aspreviously described.

The methodology advances to block 155 and the pouch 10 is finished in afinishing operation. For example, the edges of the pouch 10 are trimmedto achieve a predetermined shape. In addition, the pouch 10 may becooled at a cooling station, where the pouch 10 is cooled using aconventionally known cooling technique. Optionally, the sleeve may beplaced over the filled pouch and shrunk to fit over the pouch byapplying heat. The sleeve layer forms an outer layer of the pouch.

In block 160 the filled pouch 10 is discharged from the machine. Aplurality of pouches may be placed in a package for sales or shippingpurposes.

It should be appreciated that the pouch may undergo other processingsteps, such as an upstream oxygen purging station, a downstream oxygenpurging station, pasteurization or the like. For example, the filledpouch 10 may be pasteurized in an integral retort chamber (not shown)that heats and then cools the pouch 10. The pouch 10 may be tested, suchas burst testing or the like prior to packaging for shipping. Theseadditional processing steps may take place at a station on theform/fill/seal apparatus, or on another apparatus.

It should be appreciated that the order of steps may vary depending onthe pouch and its features. Also, a particular manufacturing station mayperform one or a plurality of operations, to enhance the efficiency ofthe methodology and apparatus.

Referring to FIG. 9, an example of a form-fill-seal machine 200 forcarrying out the method described with respect to FIG. 8 is illustrated.Various styles of machines 200 are contemplated for forming or fillingand sealing the pouch 10, such as a flat bed, conveyor or the like. Anexample of such a machine is manufactured by Nishibe, such as the modelnumber SBM500, SMB600 or SMB700. The machine 200 may include formstations 210 and/or fill-seal stations 258. It should be appreciatedthat a particular manufacturing station may perform one or a pluralityof operations, to enhance the efficiency of the methodology andapparatus. The stations may be arranged in a linear manner, rotarymanner, or a combination thereof.

The machine includes a base 216 and a transport device 212 thattransports the material through the various stations. Various styles oftransport devices are contemplated, and a particular machine may includemore than one style. An example of a transport device is a conveyor,rollers, a turret or the like. The roll of material 204 is initiallymounted along a horizontally oriented axis, and is unrolled along at amaterial feed station.

The machine 200 includes an alignment station 218 that aligns theunrolling material 204. For example, at the alignment station 218, thematerial rolls pass through sensing device, such as an optical reader,that identifies a predefined point on the material 204. This predefinedpoint may be a registration mark on the material, or the edge of thematerial 204. The machine 200 utilizes the registration marks toautomatically adjust the orientation of the unrolling material positionalong an axis. For example, rollers 220 are used to adjust the positionof the unrolling material ±2 degrees relative to a vertically orientedcenter axis.

The machine may include a fitment application station 222 that appliesan opening means 28, such as a zipper fitment to the unrolling materialat a predetermined location on the material. The machine includes afeeder mechanism 223, which supplies the opening means to the machine.In this example, a feeder mechanism 223 supplies the unrolling materialroll with the opening means at a 90 degree angle to the direction ofmaterial 204 flow. It should be appreciated that the opening means maybe simultaneously applied across all lanes in the predetermined panellocation.

The machine includes a cutting station 224 where the material is cutinto a predetermined number of sections. For a pouch made from twopanels of material, one of the sections is rotated 180 degrees, and thefirst and second sections of this example are positioned such that innersides face one another. The sections are used to form the front paneland back panel of the pouch, respectively.

The machine may include a feature insertion station that adds a feature,as previously described, between the facing sheets of material. Thefacing sections are transferred along the conveyer to a sealing station.

The machine includes a station 228 that applies a rib 50 and seals theedges of the pouch. Various techniques are known in the art for thispurpose, and more than one technique may be used. The rib 50 may bethermoformed. The edge seal may be a heat weld formed by applying heatand compression, or an ultrasonic seal formed using vibrational energy,or a combination of heat and ultrasonic seals. In addition, a previousseal may be absorbed during the sealing process.

The sealing station may include one or more seal bars 229 to form therib or to apply the seal. In an example, there are two opposed sealbars, and the pouch fits between the seal bars. The seal bar may includea surface that corresponds to a predetermined shape or the seal or rib.The sealing station 228 may form the seams joining the edge of eachpanel to delineate each pouch. In this example, the side edges of eachof the pouches along the width of material are heat-sealed. By precisealignment of the material sheets, the width of the side edge seam may bereduced, such as 4 mm, with a tolerance of ±1 mm.

The machine includes a cutting station 230 and the sealed panels areseparated into individual pouches. For example, the pouch is separatedalong an edge seam. The pouch may also be separated from the unrollingmaterial along the upper edge and lower edge. The cut may be a doublecut, so as to separate two pouches at one time. It should be appreciatedthat the pouches 10 are fully formed, and are now ready for filling.

The machine includes an unloading station 232. The transport devicetransfers the individual pouches to an unloading station 232, whereinthe individual pouches are removed. The pouches may be placed into areceptacle, such as a holder, or magazine or the like. In this example,the pouches may be placed directly on a fill-seal line 258 associatedwith the machine, using a robotic transfer device 252.

For a form-fill-seal machine, the line speed between the form stations210 and the fill-seal stations 258 can be coordinated to output filledpouches at a predetermined rate, and such coordination may increase theoverall pouch production rate. The fill-seal line 258 includes a pouchreceiving station 234 for receiving the pouch that includes a pouchcarrier 262 that moves the pouch, arranged in a predetermined manner,through each of the stations in the fill-seal line 258. The fill-sealstations may be associated with a second frame 284. The stations of thefill seal line 258 of the machine 200 may be arranged in variousconfigurations, such as a linear manner, or a circular manner. Anexample of a circular transport means is a rotational transport table.The linearly arranged stations may be further oriented transversely orvertically. Various types of pouch carriers are available, such as aholder 262 or a gripper, a combination thereof or the like. An exampleof a holder 262 is a cup-shaped member, as disclosed in commonlyassigned U.S. patent application Ser. No. 10/336,601, which isincorporated herein by reference. Another example of a holder is a pairof opposed edge grippers 264 that each hold a corresponding side edge ofthe pouch. The side edge grippers 264 may be operatively connected to anactuating device for displacing the side edge gripper to open the pouch.The holder 262 is operatively connected to a transport device 282 formoving the pouch carrier between stations.

The machine includes an opening station 236, in order to separate theupper edges of the pouch for filling. The opening station 236 mayinclude panel grippers 266 that grip the outside panels of the pouch.The opening station 236 may also includes a pouch opening device forfully opening the pouch. An example of a pouch opening device isdisclosed in commonly assigned U.S. patent application Ser. No.11/933,784 which is incorporated herein by reference.

After the pouch is fully opened, a stream of heated air may be directedtoward the upper edges of the pouch, or through the spout. In addition,a nozzle may be mechanically lowered into the pouch opened 10. Thenozzle is secured to a gas supply means. For example, a stream ofcompressed gas downwardly into the pouch to further force the walls ofthe pouch 10 away from each other to further the pouch as shown at 238.An example of a gas is carbon dioxide or nitrogen.

In addition, the opening station 236 may include a manifold, with a hoodextending over the top of the edges of the pouch. The manifold has rowsof apertures (not shown) formed above the upper edges of the walls ofthe pouch. The hood is placed over the pouch to assist in maintainingthe air pressure in the pouch. The supply of pressurized gas is directedthrough the aperture to form a plurality of jets of pressurized gas orair. The jets are directed downwardly at the diamond-shaped openingsformed at the upper edges to assist in overcoming the surface tension ofthe walls and assist in separation of the walls. A diving rod may thenbe used to make sure the pouch is fully opened. Steam or another type ofsterilizer may be utilized to clean an inside wall of the opened pouch.

The opened pouch moves to a filling station 240, and the pouch is filledwith the product. For example, a product is stored in a storage device,and one end of a feed line is in communication with the product in thestorage device. The other end of the feed line is secured to a nozzlethat dispenses a predetermined amount of product into the opened pouch.The product may be dispensed directly through the opened edges of thepouch or through the spout. The feed line is operatively controlled byan actuator that lowers the nozzle into the opened pouch, and dispensesthe product into the opened pouch. The nozzle may be raised at apredetermined rate out of the pouch that corresponds to the rate offilling the pouch. The controlled delivery of product may reduce anyoverspray. Depending on the size of the pouch, there may be multiplefill nozzles or fill stations.

If carbonation is desired, and the product is naturally carbonated, suchas beer or soda or the like, the pouch may be filled while immersed in anitrogen atmosphere. If the product is not naturally carbonated, it maybe immersed in a carbonator to introduce carbon dioxide into theproduct. For example, carbon dioxide is introduced into cold water orjuice to provide a carbonated beverage. The product may contain amixture of up to four volumes of carbon dioxide. It should beappreciated that the carbon dioxide may also mask any undesirable tastefrom ketones and other solvents released during the sealing process. Thecarbon dioxide also increases the pressure within the product so thatthe walls of the pouch 10 are rigid after the top is sealed. The productis preferably filled at a temperature ranging from 29° F. to ambienttemperature. The carbonation is also advantageous as a microbiocide thatcan enhance the flavor or prevent mold or contamination.

The machine includes a gas removal station for removing any oxygen fromthe pouch as shown at 242. The gas removal station may include a hoodthat evacuates the oxygen, or a diving nozzle that delivers a gas, suchas carbon dioxide or nitrogen, or liquid nitrogen or the like, into thepouch to displace the oxygen.

The machine includes a closing station 244 that closes the pouch. In anexample of a pouch includes a zipper fitment, the zipper is closed usinga closing apparatus that engages the zipper, and a portion of the pouchoutboard of the zipper may be sealed. In another example of a pouchfilled through the open edges of the pouch, the closed edges of thepouch are sealed using a closing seal. The closing seal may be a thermalseal. For example, a moveable heat sealing member is positioned over theupper edge of the pouch to seal the upper edges together through theapplication of heat or heat and pressure. Another example of a closingseal for a product utilizes an ultrasonic sealing process that includesa first closing seal. The ultrasonic seal may include sound waves and isformed using a horn and anvil.

The machine may include a second closing station for applying a secondclosing seal. The second closing seal may be applied using a heat sealmeans to form a second heat seal spaced apart a predetermined distancefrom the first closing seal. It should be appreciated that the secondclosing seal may be spaced slightly outboard of the first closing seal.The second heat-sealing station is conventional and utilizes heat or acombination of heat and pressure to form the seal. The second closingseal may also be a cosmetic seal or another type of seal, such asultrasonic, ultra pulse or the like. The first and second seals areapplied for a carbonated product as disclosed in commonly assignedPatent Application No. PCT/US03/34396, which is incorporated herein byreference.

If the pouch 10 is filled through the spout fitment, the pouch 10 isclosed by securing a cap 36 to the spout 34 using a cap applicationdevice. The cap 36 may have a tamper-evident feature. In addition, thecap 36 may contain a tracking device 26.

The machine includes a removal station 246 for finishing and removingthe pouch from the machine 200. A feature, such as a hanging aperture44, may be formed at this time using a cutting device, such as a punch.In another example of a finishing operation, the edges of the pouch 10may be trimmed to achieve a desired shape using a cutting device.

The machine includes a pouch transfer device such as a robotic transferdevice for removing the pouches 10 from the machine 200. The pouch maybe placed into a box or moved to another device or machine foradditional processing.

It should be appreciated that the automated machine 200 may includeother operations. For example, the filled pouch may be transferred toanother transport device, or otherwise collected. Alternatively, otherstations may include a straw pierceable opening station, an upstreamoxygen purging station, downstream oxygen purging station, or the like.In another example, the pouch is transferred to a packaging machine,which may be integral with the fill-seal machine or a separate line.Still another example of additional processing is the pouch may betransferred to a pasteurization station. Pasteurization enhances theshelf life of the product. The pouch is inserted into an enclosedchamber. For example, a combination of steam and water is used to heatthe pouch to a predetermined temperature for a predetermined period oftime to pasteurize the product contained within the pouch. The packageis then cooled. In certain instances, it may be desirable to apply steamto sterilize the pouch 10 and to wet the inner surface of the walls tofacilitate handling.

The finished pouch is available for use. It should be appreciated thatthe ribs 50 provide structural rigidity to the filled pouch 10, and thepouch 10 stands upright unassisted even as the product is removed.

The present invention has been described in an illustrative manner. Itis to be understood that the terminology which has been used is intendedto be in the nature of words of description rather than of limitation.

Many modifications and variations of the present invention are possiblein light of the above teachings. Therefore, the present invention may bepracticed other than as specifically described.

1. A stand-up flexible pouch for packaging a product, said pouchcomprising: a panel forming a body of the pouch using a flexiblematerial having an inner surface and an outer surface; a rib integrallyformed in the pouch body, wherein the rib is spaced a predetermineddistance from an edge of the panel and forms a shaped edge of the pouch;and an opening means integrally formed in said panel for accessing theproduct contained within the pouch.
 2. The pouch as set forth in claim 1wherein the pouch holds up to 20 L of the product.
 3. The pouch as setforth in claim 1 wherein the rib has a height that is less than athickness of the flexible material.
 4. The pouch as set forth in claim 1wherein a second rib is spaced a predetermined distance apart from afirst rib.
 5. The pouch as set forth in claim pouch 1 wherein the rib isthermoformed in the panel, such that the outer surface of the flexiblematerial is convex in shape.
 6. The pouch as set forth in claim pouch 1wherein a shape of the rib corresponds to a shape of a side edge of thepouch body.
 7. The pouch as set forth in claim pouch 1 wherein the pouchbody includes a front wall and a back wall and a gusset positionedbetween the front wall and the back wall.
 8. The pouch as set forth inclaim 1 wherein said opening means includes a fitment and a capremovably attached to said fitment.
 9. A stand-up flexible pouch forpackaging a product, said pouch comprising: a panel forming a body ofthe pouch using a flexible material having an inner surface and an outersurface; a plurality of ribs integrally formed in the pouch body,wherein each rib is thermoformed in a wall of the pouch body and forms acorresponding shaped edge of the pouch body; and an opening meansintegrally formed in said panel for accessing the product containedwithin the pouch.
 10. The pouch as set forth in claim 9 wherein the ribhas a height that is less than a thickness of the flexible material. 11.The pouch as set forth in claim 9 wherein the pouch holds up to 20 L ofthe product.
 12. The pouch as set forth in claim pouch 9 wherein the ribis spaced a predetermined distance form a side edge of the pouch body.13. The pouch as set forth in claim pouch 9 wherein the pouch bodyincludes a front wall and a back wall and a gusset positioned betweenthe front wall and the back wall.
 14. The pouch as set forth in claim 9wherein said opening means includes a fitment and a cap removablyattached to said fitment.
 15. A method of forming a stand-up flexiblepouch on a machine, said method comprising the steps of: unrolling alaminate material across lanes of a high speed machine; thermoforming arib in the material; forming a body of the pouch from the material,wherein the body of the pouch includes a wall having an edge, and therib is positioned to form a shaped edge of the pouch; and applying anopening means to the pouch.
 16. The method as set forth in claim 15,further including the steps of: opening the pouch; filling the pouchwith the product; and closing the pouch.
 17. The method as set forth inclaim 15 further including the step of thermoforming a plurality of ribsto form a corresponding shaped edge of the pouch.
 18. The pouch as setforth in claim 15 wherein said opening means includes a fitment and acap removably attached to said fitment.